mk2 golf mtdi build-daily to be

thought its about time to start a build thread, got teh mk2 after a fair hunt over a month ago now. intention was to slap it all together ready for edition38 show. ended up getting the car to close to the show and not enough time to make the car i wanted and didnt want to rush it.

have a mk4 gt tdi currently, great dailey but doesnt have that nice old feel like the mk1s and 2s ive had, so thought ide make the best of both, good mpg and power and the older feel, plus im starting to get nice and busy with doing the wheel refurb and getting the new buissness under going i done like carting wheels around inside the mk4 and plopping loads of parts and tools on the seats.

so basic outline of the build, cleanish shell, with mtdi engine (tdi running a manual pump, td) t3 turbo. everything new, and painted/powdercaoted. nice interior with a stripped out rear so i can pick wheels up and drop them off to customers, home brew motorsport poopfer, cable change mk3 tdi gearbox, bigger stoppers, oem wheels with a healthy slam.

so for starters heres the car, originaly a small bumper and had big bumpers put on it, so will be going back to small bumpers in the end when it goes back together





so, the plans changed after the car not going to edition, game upped a fair bit and time todo it the propper way. so, the tdi lump was completely stripped out, pistons out, crack etc. then went off to cambridge rebores, rehoned, crack polished and engine cleaned inside and out, new rings and all the bearings purchased ready for rebuild.




minty fresh starting point



onto the block, all the gunk inside and out had been stripped, so took the rust etc off teh black and heat painted it


painted


so with a nice clean block, started stripping the parts, cleaning, blasting and painting them ready for refit







the fist pile of new parts


and the engine as it stands, with new water pump painted to match the other engine parts, painted bolts and stainless nuts so everythings nice clean and fresh




next up is armor the sump, blast and paint that ready to fit once the internals go back in. then can make a start on the head and get ready to mount the new pump and t3 turbo.

so yesterday i pulled the engine out ready to start cleaning the bay out, plans are to have a minimalistic deisel bay, loom tuck and wrap, no header tank, hidden washer bottle and a few other trick bits in the making, big alloy rad and intercooler are being made by a mate too. so will be very different once done.

as for now it looks a little dirty





new interior to come soon too, upgrading from driver grandad spec to some tidy recaros.

cheers for looking and reading all comments welcome.......

Hope your keeping the grille

Nice work joe

What did the block work set you back at cambridge rebores?

matty_mk1 wrote:

Hope your keeping the grille

i thought ide keep it for you dude, can swap it for those rectangular lights on yours

CaddyRage wrote:

Nice work joe

What did the block work set you back at cambridge rebores?

cheers man, i think the rehone is something like £8 per bore, £9 per jernal on the crack to polish off the top of my head, and the clean was suppose tobe |£20 but i think i got that free after buying all the parts with them

Did you fit all the bits the right way round?

Good work dude, keep the updates coming...

a mk2!!!

ill be keeping an eye on this as it sounds like its gonna be sweet at the end

looking good joe when you putting a cage in it lol

mtdi dont work like that mate :( trust me i tried it on my mk2, 1.9 tdi with a modified TD pump and it was absolutely shite, slower than a standard TDi. You need huge fuel pressures to make a mTDi work.

VW Mike wrote:

Did you fit all the bits the right way round?

havent put anything else on since you was over dude, except getting the stainless bolts for the water pump bracket

MK1G60 wrote:

Good work dude, keep the updates coming...

cheers man, will keep updating in blocks to there progress each time

bridgedubber wrote:

a mk2!!!

ill be keeping an eye on this as it sounds like its gonna be sweet at the end

i hope so

caddyman wrote:

looking good joe when you putting a cage in it lol

im not now, wont be user friendly with putting wheels inte h back, will have to un wrap my self each time i try to put somethingin the back lol

Tiz wrote:

mtdi dont work like that mate :( trust me i tried it on my mk2, 1.9 tdi with a modified TD pump and it was absolutely shite, slower than a standard TDi. You need huge fuel pressures to make a mTDi work.

bloke on the caddy forum is running one whos gave me all the details, hes been destroying clutches for months and just payed silly money for some crazy piece of metal

looking good ill keep my eye on this

Tiz wrote:

mtdi dont work like that mate :( trust me i tried it on my mk2, 1.9 tdi with a modified TD pump and it was absolutely shite, slower than a standard TDi. You need huge fuel pressures to make a mTDi work.

bloke on the caddy forum is running one whos gave me all the details, hes been destroying clutches for months and just payed silly money for some crazy piece of metal [/quote]

Seen it in action or is he just an internet hero? What details did he give you? You can build a pump to do it but i can assure you its not just a bolt it on jobbie.

Tiz wrote:

Tiz wrote:

mtdi dont work like that mate :( trust me i tried it on my mk2, 1.9 tdi with a modified TD pump and it was absolutely shite, slower than a standard TDi. You need huge fuel pressures to make a mTDi work.

bloke on the caddy forum is running one whos gave me all the details, hes been destroying clutches for months and just payed silly money for some crazy piece of metal

Seen it in action or is he just an internet hero? What details did he give you? You can build a pump to do it but i can assure you its not just a bolt it on jobbie.[/quote]

not seen it in action of corse no, he gave me loads, many pms obviously im not going to put them in here as they are mainly questions asked by me and answered by him. i suppose ile find out once my pump arrives and its in the car

whats been done to the pump then?

Tiz wrote:

whats been done to the pump then?

if i tolld you that idea have to kill you, no one wants that

just trying to help lol to make sure it will work cause i did it and built a custom pump and it was s**t couldnt get enough pump pressure without actually using a DI pump off something like a landrover.

i no, i dont want to say i done this this n this and then it work or not work, ide rather try fail or get it working then say, if it doesnt work then ile change the plan

that doesnt make any sense but....keep on truckin'

if you think about it, it makes sense.

big bumper mk2s are gay, but a million times better than a mk4. this car is billybug approved.

billybug wrote:

if you think about it, it makes sense.

big bumper mk2s are gay, but a million times better than a mk4. this car is billybug approved.

ha even billy agress


where have you been hiding man? read the thread, its going small bumper yooo

billybug approved means nothing. he likes fiat pandas!

curtis_caddy wrote:

billybug wrote:

if you think about it, it makes sense.

big bumper mk2s are gay, but a million times better than a mk4. this car is billybug approved.

ha even billy agress


where have you been hiding man? read the thread, its going small bumper yooo

you know i cant read, i can only look at pictures.

i have been riding all day everyday this summer and never on the computer, but now my leg is in a cast yet again ill be on here more haha

69rat wrote:

billybug approved means nothing. he likes fiat pandas!

whaaat! no way, must be a right chav homo

billybug wrote:

curtis_caddy wrote:

billybug wrote:

if you think about it, it makes sense.

big bumper mk2s are gay, but a million times better than a mk4. this car is billybug approved.

ha even billy agress


where have you been hiding man? read the thread, its going small bumper yooo

you know i cant read, i can only look at pictures.

i have been riding all day everyday this summer and never on the computer, but now my leg is in a cast yet again ill be on here more haha

ha you nugget! best get finding some cool us metal for you to play with in those winter months!

went for a long drive last night, met up with spen. lovely bloke, and i swapped some wheel parts for him rms and in return got a minty fresh recaro interior, gave it a bit of a wet vax today, didnt work overly well so need to fix the machine and have another go.

steve popped over and we gutted the car, hoovered under the carpets, carpets only now resting in places as im going to die them so there a bit more fresh looking, door cards in and seats test fitted, i have teh genuine loom for the seats too but not put it in yet, they will go in finaly once the carpets go back in for good after i fitted the pedal box for the hydro clutch.

for now a few pics from today....

not updated this in a couple weeks so here goes...its a big one.

so last weekend steve came over, while i got the wheel stand ready for the AF stand for the players show he ripped the loom out for me, took the unwanted crap out the bay and cut the wiring for the "alarm" out.

next up was takling the crappy bay, loads of build up of grime from the last 20 years, so hooked some cleaner out the parts washer and gave it a soaking, then got the pressure washer out and blasted it off. stood it back up the side of the house and steve got to work getting the subframe off.

the loom


"crap pile"


bay....









and a picture of both the dea wings, great arch mods and nice amount of sealer, and they still pretty much dropped off!



in the week i got the subframe in bits ready to blast then off to the coaters


from this week, thursday friday and saturday (today) me and steve hit hard with out first "the 3 day bay"

DAY 1
blasted seams, all rust gone, and the bottom half smooth stone chipped, unwanted brackets cut and drilled out, lugs etc cut off.












DAY 2
all the unwanted holes welded up, zinc primed. then out with the filler, couple skims then a whip over with dolphin glaze. primed to keep it all safe for the night and then dabbed seam slear over the lines that we rubbed off with the sand paper and DA, wanted to get a nice original feel to it to made sence.







DAY 3
high build primer, flatted to get all the little ends faded out we missed in the dark, was outside til gone 9! primed, wet flatted, wiped down, heater on, 4 coats of paint 2 clear coats. oh and a fly that wanted to join in and landed on a chasis leg, the one place everyone will see!











and it was all done in the £16.99 argos special gazibo with a big sheet over the top



oh, and all painted with cans!

i nearly popped over today but saw you had that sheet up ha, looking really good and quicker then the caddy engine bay mate !